Packaging support structure

ABSTRACT

Apparatus and related methods directed to packaging support structures having a material with first and second outer layers spaced apart from each other by a spacer layer defining a plurality of voids between the first and second outer layer. The material can include a plurality of through-slots extending through the material and along a first direction. The material can be foldable in the region of the slots to produce a central fold along a second direction, substantially perpendicular to the first direction. The packaging support structure can accommodate a plurality of respective products in the slots such that the products and slots cooperatively provide a stiff resultant structure that is resistant to compression forces along the second direction with the central fold enabling the material between the slots to extend into a space created between the products providing resistance to compression forces over a significant portion of the product area.

FIELD OF THE INVENTION

The present disclosure relates to a packaging support structure, for example a lightweight packaging structure conferring high protection to external mechanical forces.

BACKGROUND OF THE INVENTION

Packaging is a key aspect in preserving product integrity, function and safety during handling, transportation and use. Common requirements for packaging are low cost, light weight and reasonable resistance to mechanical forces. In this regard, the use of corrugated materials has now become widespread in the packaging industry. The most notable example is paperboard although corrugated plastic sheets, overcoming some of the limitations associated with cellulosics, such as water absorption and consequent loss of mechanical properties, are also becoming standard in packaging. One example of such a material is alveolar polypropylene.

Alveolar materials, for example, comprise corrugated materials sandwiched between sheet layers and are designed and manufactured to offer adequate strength at low weight. In particular, strength in the direction of alveolar/corrugated walls is considerably higher than in the other directions and package folding ensures that this reinforcement is present in various directions. However, reinforcement is mostly concentrated at or near the edges (folds), and in the direction of the reinforcing walls. Typically the package faces are susceptible to impact and mechanical forces, in particular forces applied substantially perpendicular to relatively large area faces of the packaging.

It would therefore be desirable to provide additional support for packaging products, in particular where the products have pressure sensitive areas, such as elements protruding from an otherwise planar product. Aspects of this disclosure provide additional support structures for the product inside the package which may be of the same or of different material than the support structures. Beneficially, these internal structures provide adequate strength at low cost, are light weight and may enable high density packaging in order to minimise packing volume.

SUMMARY OF THE INVENTION

Aspects of the invention provide a packaging support structure comprising a material having first and second outer faces or layers spaced from each other by a spacer layer defining a plurality of voids between the first and second outer layer. A plurality of through-slots extending through the material and along a first direction are provided. The material is foldable in the region of the slots to produce a central fold along a second direction, substantially perpendicular to the first direction.

Advantageously, the described packaging support structure is able to accommodate a plurality of respective products in the slots in such a way that the products and slots cooperate to provide a stiff resultant structure that is resistant to compression forces along the second direction, the central fold in the second direction enabling the material between the slots to extend into a space created between the products to provide resistance to compression forces over a significant portion of the product area.

In some embodiments, a central cut along the second direction in one of the first or second layers facilitates folding the structure to produce the central fold by locally reducing the bending resistance of the material. This is particularly advantageous in embodiments where the planar stiffness of the material is high in the first direction. In some embodiments, the central cut is central in the sense that it bisects the through-slots. In other embodiments, the central cut may be off-centre to the through-slots to provide an asymmetric configuration.

In some embodiments, respective further cuts along the second direction can be present in the first or second layer on one or both sides of the plurality of slots to facilitate folding the structure to produce a respective further fold to one or both sides of the plurality of through-slots. Advantageously, this provides a side portion on one or both sides of the plurality of slots to support and stabilise the packaging support structure and products inside the packaging and further enable a more acute angle to be provided relative to the central fold than would otherwise be the case for given packaging and packaging support dimensions.

In some embodiments, the various cuts are made in the same outer layer (on the same side of the material). In other embodiments, one or more of the cuts are made in different layers, for example the cuts to the side of the plurality of slots being in one layer and the central cut being in another layer. The former has the advantage of increased manufacturing efficiency, while the latter ensures that all folds either open up to the outside or compress material to the inside, depending on the orientation of the folds.

It will be appreciated that the above embodiments are not limited to a single cut for each fold, but rather one or more additional cuts can be made in the region of one or more of the folds to facilitate folding, without departing from the above embodiments.

The material can be a sheet material in some embodiments, for example alveolar polypropylene. The spacer layer can comprise walls defining the voids there between and extending between the first and second outer layer and through the spacer layer along the second direction. This is advantageous since the high-strength direction of the material along the direction of the walls is aligned with the second direction along which compressive forces that can press objects in the slots together would act. This alignment therefore facilitates the overall strengthening of a combination of the support structure with objects in the slots along this direction, in particular where the wall portions between the slots are relatively short, which also facilitates improved packing density. However, other orientations of the walls are equally possible in other embodiments.

The spacer layer can comprise a corrugated sheet material. In some embodiments, the spacer layer comprises a spacer layer in which a cellular structure defines the voids. The spacer layer can be provided by any suitable lightweight material providing a layer of voids between the first and second outer layer, for example a rigid foam or honeycomb material.

The material can be folded in such a way that one or more of the cuts are on the outside of their respective fold, thereby opening up the spacer layer in the region of the cut and facilitating consistent folding. Alternatively, one or more of the cuts can be disposed inside the respective fold, adding strength to the structure by compression of the spacer layer in the fold.

Aspects of the invention extend to a packaging support structure as described above in combination with one or more objects to be packaged inserted in each slot. Advantageously, this arrangement can provide a high strength structure by virtue of an intimate fit between the objects and the support structure, as discussed above. For example, the objects can be disc-shaped. The arrangement is particularly advantageous where the objects have a protrusion extending from a disk or otherwise plate shaped portion, in that the material of the packaging support structure between the slots alleviates pressure on the protrusions. This is particularly advantageous where the protrusion is pressure sensitive, for example where the object is a lab-on-a-disk analytical device having a blister pouch with liquid, for example a buffer or reagent solution, secured to it. Space saving efficiencies can be achieved in embodiments where two such objects with respective protrusions are mounted back-to-back in a slot so that the protrusions face outward. Interference with protrusions from an adjacent slot can be avoided in such embodiments by appropriately orienting the discs in adjacent slots.

Aspects of the invention further extend to a container containing one or more packaging support structures for packaging support structures in combination with objects as described above. In embodiments where there is more than one packaging support structure, the packaging support structures can be arranged inside the container to be aligned along the second direction and/or to be disposed around the products about the second direction.

The container can be made by folding a material and can have outer surface areas which are prone to bending and deformation leading to ingress into the product containing space inside the container and application of pressure to products inside the container. Advantageously, packaging support structure(s) inside the container can be oriented such that the second direction is perpendicular to this outer surface area, thereby significantly strengthening the overall packaging in the direction in which this is most beneficial.

To facilitate the structural support function described above, the inner dimension of the container in the second direction can be substantially the same as the dimension of the one or more packaging support structures in that direction (total dimension in case of two or more packaging support structures stacked in that direction). The inner dimension of the container in the first direction can be smaller than the dimension in the first direction of the one or more packaging support structures to urge and maintain the packaging support structure into a folded configuration so that the interstitial material between the slots extends inside the space between the packaged objects in an intercalated fashion to provide support.

The above summary of the various representative embodiments of the invention is not intended to describe each illustrated embodiment or every implementation of the invention. Rather, the embodiments are chosen and described so that others skilled in the art can appreciate and understand the principles and practices of the invention. The figures in the detailed description that follow more particularly exemplify these embodiments.

BRIEF DESCRIPTION OF THE FIGURES

A specific embodiment is now described by way of example to further the understanding of the present disclosure, with reference to the accompanying drawings in which:

FIG. 1 is a top perspective view of a packaging support structure according to a representative embodiment of the present invention.

FIG. 2 is a top perspective view of an object to be packaged with the packaging support structure of FIG. 1 according to a representative embodiment of the present invention.

FIG. 3 is a side perspective view of a plurality of objects packaged in respective metal foil pouches and held in slots of a pair of the packaging support structures of FIG. 1 according to a representative embodiment of the present invention.

FIG. 4 is a top perspective view of a foldable container enclosing a pair of the packaging support structures of FIG. 1 according to a representative embodiment of the present invention.

While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments as described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE FIGURES

With reference to FIGS. 1 and 2, a packaging support structure 1 is provided by an alveolar polypropylene sheet 2 having first 4 and second 6 outer faces or layers connected by walls 8 forming a spacer layer 9 between the first 4 and second 6 outer faces. The spacer layer 9 spaces the first and second outer faces 4 and 6 apart and defines voids 11 extending through the sheet 2 between the outer faces and respective adjacent webs 8. Mutually spaced slots 10 are cut through the alveolar polypropylene sheet 2 in a direction perpendicular to the direction of the voids 11 to define a product supporting region 12. The slots 10 are spaced along the direction of the voids 11. Respective cuts 14 on either side of the slots 10 in the first outer face 4 in the direction of the voids 11 define side portions 16 to the side of the product supporting region 12 and facilitate folding of the side portions 16 relative to the product supporting region 12 with a first fold 15 and a second fold 17. A central cut 18 in the first outer layer 4 in the direction of the voids 11 facilitates folding of the product supporting region 12 along a central fold 19 to facilitate intercalating product supporting arms 20 defined between the slots 10 with products held in the slots 10, as will be described below. While cuts 14 and central cut 18 are described and illustrated as being defined in the first outer layer 4, it will be understood that they can be similarly defined in second outer layer 6 while in some embodiments, cuts 14 can defined on opposed sides of sheet 2 with one each in the first and second outer layers 4 and 6.

With reference to FIG. 2, a lab-on-a-disk analytical device 22 is a type of product that can be packaged with the described packaging support structure in a particularly advantageous fashion. Lab-on-a-disk analytical device 22 can include a device body 24 comprising a disk shaped or CD-like substrate housing microfluidic structures as is known in the art and will not be described here in further detail. Device body 24 can include a protrusion 25, such as, for example, a blister pouch 26 in the case of lab-on-a disk analytical device 22. Blister pouch 26 can contain buffer solution or, in other embodiments, another liquid. The blister pouch 26 is arranged such that digital pressure on the blister pouch 26 ruptures a membrane between the blister pouch 26 and the device body 24 to introduce the liquid into the device 24 to enable analysis to be carried out. Premature rupturing of the blister pouch 26 during transit spoils the lab-on-a-disk analytical device 22 for further use. It is therefore particularly advantageous to package the lab-on-a-disk analytical device 22 in a fashion that alleviates pressure on the device along a direction perpendicular to the surface.

With reference to FIG. 3, a plurality of lab-on-a-disk analytical devices 22 are packaged in respective metal foil pouches 28 and held by a pair of the packaging support structures 1 in their respective slots 10. To this end, the side portions 16 are disposed relative to each other such that the spacing between them is less than the width of the product supporting region 12 and the product supporting arms 20 are folded to extend inward from the side portions 16. In this fashion, the product supporting arms 20 are intercalated between the metal foil pouches 28. Each slot accepts two metal foil pouches 28, which are arranged such that the lab-on-a-disk analytical device 22 in each metal foil pouch 28 inside one slot are arranged back-to-back with the respective blister pouch 26 facing outward. The lab-on-a-disk analytical devices 22 are oriented such that the blister pouches 26 are disposed in between or to one side of the product supporting arms 20, so that pressure perpendicular to the surface of the devices which would risk rupturing the blister pouch 26 is absorbed by the product supporting arms 20. The slots are dimensioned such that two metal foil pouches 28 are a close fit with each slot 10, so that the pouches/devices and slots cooperate to provide a high-strength packaging interior in the direction of the voids in the packaging support structure. As illustrated by the example in FIG. 3, the metal foil pouches 28 are supported by two packaging support structures, intercalating at a total of four product supporting arms 20 between pairs of metal foil pouches 28.

With reference to FIG. 4, the combined packaging support structure and foil pouches/devices are disposed in a foldable container 30 formed by folding a sheet material 31, for example resin impregnated cardboard or alveolar polypropylene, and having a lid portion 32. The packaging support structure is disposed inside the container such that the side portions 16 abut respective adjacent container walls to dispose the packaging support structure in a well-defined configuration by constraining the side portions 16 to a mutual distance less than the flat length of the packaging support structure, as discussed above. Further, the inner dimension of the container perpendicular to the lid portion 32 (when closed) is arranged to be substantially the same as the outer dimension of the packaging support structure in the direction of the voids, such that the packaging support structure together with the metal foil pouches it carries significantly strengthens the vulnerable lid portion 32 of the container 30 and the opposed floor portion (not visible in FIG. 4), by absorbing normal forces on the lid portion 32 that would otherwise bend the lid portion 32 into the container and transmitting that force through the packaging support structure to the floor portion. That way, secure stacking of the container 30 is enabled without endangering product integrity of the lab-on-a-disk analytical device.

The effectiveness of the disclosed packaging solution has been tested by a compression test, applying a significant weight to the lid portion 32 which resulted in no significant ingress of the lid portion 32 into the container interior and no damage to the lab-on-a-disk analytical devices contained inside.

While a specific embodiment has been described above by way of illustration, it will be appreciated that the described principles are equally applicable to a wide range of products, in particular although not exclusively plate like configured products which have one dimension significantly smaller than the other two, in addition to a wide range of disk-shaped products other than lab-on-a-disk analytical devices. Products can be packaged one, two or more to a slot, as convenient for a given application. Equally, while specific materials have been described in the context of the embodiment described above with reference to the drawings, a wide range of materials having sheet-like outer layers separated by a lightweight spacer layer may be used for the packaging support structure and, indeed, the container. These materials may be of an alveolar, cellular, foam-like or any other suitable configuration. Further, different materials may be used for the container, if desired. Similarly, the number, dimensions and configuration of the described packaging support structure(s) will readily be adapted by a person skilled in the art without departing from the described principles.

More generally, numerous adaptations, modifications, combinations and juxtapositions of the features described above may be made without departing from the described principles. 

1. A packaging support structure comprising a material having first and second outer layers spaced from each other by a spacer layer defining a plurality of voids between the first and second outer layers, the packaging support structure defining a plurality of slots extending through the material and along a first direction, wherein the material is foldable in the region of the slots to produce a central fold along a second direction, substantially perpendicular to the first direction.
 2. The packaging support structure of claim 1 defining a central cut along the second direction in the first or second layer to facilitate folding the material to produce the central fold.
 3. The packaging support structure of claim 2 defining a first cut along the second direction in the first or second layer to facilitate folding the material to produce a first fold to one side of the plurality of through-slots.
 4. The packaging support structure of claim 3 defining a second cut along the second direction in the first layer or second to facilitate folding the material to produce a second fold to the other side of the plurality of through-slots from the first fold.
 5. The packaging support structure of claim 4, wherein the first cut and the second cut are in the same first or second outer layer as the central cut.
 6. The packaging support structure of claim 4, wherein at least one of the first cut or the second cut in the different first or second layer as the central cut.
 7. The packaging support structure of claim 1, wherein the material is a sheet material.
 8. The packaging support structure of claim 1, wherein the spacer layer comprises a plurality of walls defining the voids there between, the walls extending between the first and second outer layer and through the spacer layer along the second direction.
 9. The packaging support structure of claim 1, wherein the spacer layer comprises a corrugated sheet material.
 10. The packaging support structure of claim 1, wherein the spacer layer comprises alveolar polypropylene.
 11. The packaging support structure of claim 1, including one or more objects to be inserted and packaged in each slot.
 12. The packaging support structure of claim 11, wherein the one or more objects are disc-shaped.
 13. The packaging support structure of claim 11, wherein each object has a protrusion extending from a disc-shaped body and wherein two objects are mounted in a shared slot with the protrusions facing outwards.
 14. The packaging support structure of claim 13, wherein the one or more objects are lab-on-a disc devices and each protrusion comprises a liquid pouch.
 15. The packaging support structure of claim 14, wherein the liquid pouch contains a buffer solution.
 16. A container containing one or more packaging support structures of claim
 1. 17. The container of claim 16, wherein the container is constructed by a folding a container material.
 18. The container of claim 17, wherein an inner dimension of the container in the first direction is smaller than the dimension of the unfolded one or more packaging support structures in the first direction.
 19. The container of claim 17, wherein an inner dimension of the container in the second direction is substantially the same as the dimension of the one or more packaging support structures in the second direction. 